Monitored Hazardous Liquid Spill Recovery System

ABSTRACT

A novel hazardous liquid recovery system provides a portable vacuum recovery into multiple storage containers, each associated with particular liquid. The system is computer controlled and measures and records recovered liquid volume simultaneous with the recovery event. Multiple different hazardous liquids, including different flammable hydrocarbons, fuels, and oils can be recovered by a single unit.

BACKGROUND OF THE INVENTION

The invention pertains to devices and systems for recovering small incidental volumes of hazardous liquids by vacuum such as occurs in automobile services facilities. Incidental spills are those that occur as a consequence of activities in which hazardous liquids are present but are not the primary process or transport material. Generally, such hazardous liquid spills have volumes of five gallons or less.

Handling and recovery of hazardous liquids are generally regulated and spill recovery efforts typically must include tracking and monitoring of liquid volumes. In the past, this has been done by manual methods that require manual measurement of volumes or amounts and manual recording of this data. These past methods are time consuming and prone to errors. What is needed is a method of recovering hazardous material while automatically recording the recovery event and the information defining the recovery activities.

SUMMARY OF THE INVENTION

The invention includes methods of vacuum recovery of liquids in which recovery event activities data including recovered volumes may be automatically recorded. A mobile system includes recovery containers and conduits communicating to a vacuum source and liquid pickup that enable recovery of liquids to identified containers. Liquid volumes are automatically measured and recorded in a computer operated control device.

Multiple separate recovery containers are included on the mobile system to enable recovery and storage of multiple different liquids. A manifold system is critical to maintaining separate the different liquids during and after recovery activities. In various configurations, a discharge multi-port connector is included to enable discharge of recovered liquids to external storage containers.

Optionally recovery activity data is transmitted to a remote location to enable monitoring. Other novel aspects of the invention are detailed in the following discussion and associated drawings.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic presentation of the primary elements of the liquid recovery hardware.

FIG. 2 is a schematic presentation of a liquid recovery storage container and connecting operational elements.

FIG. 3 is a schematic illustration of the control module.

FIG. 4 depicts the major components of the recovery system in a portable frame.

FIG. 5 depicts a connector used in discharge of stored liquids from storage containers in the inventive system.

FIG. 6 illustrates the suction manifold of the inventive system.

FIGS. 7 a, 7 b are photo illustrations of an alternative system according to the invention, in which a transmission device is connected to a vacuum collection system.

DETAILS OF EMBODIMENTS OF THE INVENTION

The invention integrates liquid recovery flow monitoring elements and record-keeping elements in a novel combination with vacuum recovery devices and portable liquid storage containers. The flow monitoring and record-keeping elements are computer controlled and includes an user interface that allows for proper use and compliance with various recovery standards in particular applications. The type and volume of recovered and stored liquid are recorded simultaneously with the receipt of the liquid. For this reason, no manual or post-recovery measurement of liquid volumes is necessary and errors and incomplete records of events are prevented.

FIGS. 1 and 4 illustrate the same configuration of the inventive system. FIG. 1 depicts in schematic form the primary operating elements as used in a liquid recovery mode. In FIG. 1, an exemplary container 10 is illustrated to demonstrate the connections to other system components, while the connections to other container are not, for clarity, illustrated. FIG. 4 depicts the primary elements of the inventive system as configured on a portable frame. In FIG. 4, the connecting hoses and other elements are not shown for clarity.

Very generally, the system, as illustrated in FIG. 1, is a portable assembly contained on a wheeled frame 100. Recovery of liquids is accomplished by vacuum. A vacuum blower 95 is connected to one of a number of storage containers 10 retained on the frame 100 so that operation of the blower 95 induces a vacuum in the container 10. Each container 10 is connected to an external suction hose 35.

Operation of the blower 95 induces air flow into the open end of the suctions hose 35 and from there into a container 10. Incidental liquid adjacent the open end of the hose 35 is carried by the rapidly moving air stream into the hose 35 and then into the container 10. The recovered liquid is separated by gravity and retained in the container 10 while the air flow continues to the vacuum blower 95 from which the air is exhausted.

The operation is computer controlled.

The system is entirely integrated into a portable frame 100—preferably wheeled—that also retains one or more electrochemical battery 90 to power the system vacuum blower 95. The size, weight and operation of the system and frame is designed to allow manual movement and operation by a single user in typical industrial workplaces. Electrical power may be supplied by other sources including external sources, although such may impede the portability of the system.

The vacuum blower 95 may be provided by multiple individual blower units (operated together) as may be required to provide the necessary air flow with the particularly provided direct-current powered devices. Preferably, the vacuum blower 95 has a capacity in the range of 100 to 120 cfm (cubic feet per minute).

Each of the multiple containers 10 includes an electronic liquid depth sensor 11 and three liquid communicating ports through which liquids or air enter or exit the container. The first port is a vacuum port 12 that is connected via a flexible hose to a vacuum manifold 20 through an operable valve 22. The vacuum manifold is connected to the vacuum blower.

The second container port is a suction port 14 that is connected via a flexible hose to a suction manifold 30 that is, in turn, connected to a suction hose 35 or similar conduit device for manually directing system suction at a spill or other incidental quantity of liquid to be recovered.

In a recovery mode, the manifold valve 22 associated with the appropriate container 10 is operated to connect the container 10 to the vacuum blower 95 through the manifold 20. Blower induced vacuum in the container draws spill liquid into the hose and through the suction manifold 30 to be received in the container 10. By selectively operating respective container operable valves 22, recovered liquid may be drawn and received into any one of the multiple containers 10.

The hose diameter must be selected to provide the necessary air flow rate and velocity to entrain and transport liquids from . Preferably, all hose sections used in the system to transport air or air/liquid has an internal diameter of about 1.25 inches (3.2 cm).

In a discharge mode, the vacuum blower is reversed and flow directed via the vacuum manifold 20 and respective manifold valve to a container 10 to be pressurized to force the contained liquid out the third, discharge, port 16 of the container 10. As shown in FIG. 2, the discharge port 16 and suction port 14 each include passive one-way check valves to automatically direct fluid flow properly as controlled by the operation of the vacuum blower 95 and resulting pressure in the container 10.

Preferably, the discharge port 16 of each container is connected to a single shared multiple port connector 80 shown in FIG. 5 having two separable portions. The multi-port connector 80 ensures that each container is connected to an associated high volume storage vessel during discharge operation. One portion of the multi-port connector 80, connected to all discharge ports 16 is preferably accessibly located on the frame 100. The other portions of the multi-port connector 80 is connected to various associated external storage devices. By ensuring that the multi-port connecter portions can be joined in only a single unique way, joining one container 10 with a unique external storage device, proper discharge from each container 10 to its respective external storage devices can be assured at each and every use.

The hose or tube used for discharge flow may be smaller than the suction hoses as only liquid is being positively transported from the container. It may be necessary for the vacuum blower to include a bypass for operation in the discharge mode.

Each storage container 10 has a volume of preferably about five gallons (19 liters). This volume provides a useful storage capacity with respect to expected spill events while maintaining a total size and weight of the frame small enough to allow manual operation. Each container 10 and associated fittings and all other elements contacting recovered liquids should be formed of hydrocarbon impervious materials, such as metals or industry plastics known to be adaptable to such use.

A control module 40 is mounted or located on the frame. The control module 40 includes an electronic processing unit such as a computer. The control module 40 is preferably battery powered, either by the same battery as is provided for the vacuum blower 95 or by a dedicated battery. External power sources are also optional. The control module 40 is operably connected to the manifold valves 22, the vacuum blower through a relay switch or controller and all of the container level sensors 11. The control module 40 also includes data storage devices such as solid-state electronic memory to store operation history data. The control module 40 also provides a user interface and input devices typical of workstation computers to enable a user to control all functions and access stored data and enter user data.

The control module 40 is configured such that all operational activities, including vacuum blower operation, valve operation and container depths, are recorded as stored data. At the same time, user data such as personnel identification, date, and time, is collected and stored. By proper configuration of the control module 40 and the functional hardware, a complete record and history of recovery activities and recovery volumes and times may be obtained.

In inventive methods using the system described, a user initiates a recovery operation through input to the control module 40. Because rapid recovery of hazardous liquids is critical, user input and incidental actions should be minimized before active recovery of liquid begins. Preferably, in the present invention, a user inputs information to define the nature of the spilled liquid to be recovered. This definition will direct the control module 40 to energize the appropriate container valve solenoid to open the valve 22 between the container 10 and the vacuum manifold 20.

Power is also provided to the vacuum blower 95 thereby enabling vacuum recovery of liquid through the suction hose 35, the suction manifold 30 and into the connected container 10. These events and the respective container volume are stored as data in the control module 40. At the end of recovery, the control module may then record the then existing depth of the liquid in the container to provide a volume recovered. More preferably, the control module 40 accepts container depth signals continuously and displays for the user, and stores, this data.

It is valuable for various practical reasons to maintain record of user identification information with event data. For this reason, the control module 40 should prompt a user to input such information immediately after termination of the recovery event. Preferably, the control module 40 or mounted on the frame 100, an audible or visible alarm is provided to alert the user if such information is not provided within a predefined time period.

Discharge operation functions similarly to recovery so that at any time, data defining the amount and type of recovered, stored, and discharged liquids are instantaneously available in the control module.

To prevent cross-contamination between the multiple storage containers 10 it is necessary to design the suction path, from the hose 35 to each container 10, to prevent introduction of recovered liquid into any container other than that selected. This requires particular geometry of the suction manifold 30, in which entering recovered liquid may incidentally pass the entrance to one or more suction ports 14 of other containers 10. The suction manifold 30 should be configured with its connections to the various containers 10 oriented generally in a common horizontal plane. FIG. 6 is an end view of the suction manifold 30 having the general form of an elongated tube. The manifold 30 is preferably located slightly below or at the vertical level of the top of the container suction ports 14. The connecting hose 15, between the suction manifold 30 and the suction port 14 must vertically rise from the manifold before entering the suction port 14. This rise creates a liquid trap preventing gravity flow of liquid in the manifold 30 from entering, incidentally, the closed container 10 or from remaining in the connecting hose 15.

Recovery of volatile and combustible liquids, such as hydrocarbon fuels and oils, is problematic for at least two reasons. The first is that movement and the equipment required for moving such liquids may induce ignition of the liquids with consequent damage. Secondly, residue of such liquids creates a variety of hazards to individuals and the environment more generally. For this reason, it is desired to be able to recover such liquids without risk of fire or combustion and without leaving such residue. To address these issues, the invention preferably provides and using a what is here termed a “safety fluid”. The safety fluid preferably has the characteristics of preventing flashing or ignition of flammable constituents of the spill and rendering them safe for recovery after the safety fluid has been added to the surface or mixed with the spill. In addition, the safety fluid has properties of a degreaser that enables removal of oil products without leaving a hazardously slippery surface behind. In one method of liquid recovery, a volume of safety fluid is dispersed onto the liquid to be recovered. The combined liquid volume is then recovered as described above. One acceptable form of safety fluid is distributed under the name PETRO-CLEAN by the Alabaster Corporation in Pasadena, Tex., USA.

In the embodiment illustrated in the figures, a quantity of safety fluid 70 is stored on the frame 100. The particular volume amount and form of containment is not critical to the invention. Also included is a safety fluid pump 98 and spray wand 75 or other means of dispensing the safety fluid onto an exposed surface of a nearby liquid spill prior to recovery. The safety fluid must be applied in the form of a mist or atomized cloud or fine spray or the like to ensure complete coverage of the spill area.

In preferred inventive recovery methods, after the majority of the liquid has been recovered as described above, the control module 40 enables dispensing safety fluid by providing power to the safety fluid pump 98 (the spray wand 75 may include a secondary switch or trigger). Preferably, at the same time, the control module 40 closes the vacuum valve associated with container 10 to which the recovered liquid has been directed. A vacuum manifold valve then is automatically operated to direct suction to a waste container 19. This waste container 19 is specifically used to recovery and store combined safety fluid and residual recovered fluid. The spray wand 75 is then used to dispense safety fluid onto the residue liquid to be recovered. Agitation or mixing of the safety fluid with the suction hose 35 may be required. Recovery of the residue liquid together with the mixed safety fluid is then completed into the waste container 19. At the same time, the passage of the safety fluid through the suction manifold 30 at least partially cleans the recovered fluid from the suction manifold 30 and the interconnected hoses. The event of application and recovery of safety fluid should be stored by the control module 40.

While the inventive system and methods includes incorporation of safety fluid and its application and recovery, the recovery system shown and described above is operative without safety fluid where the issues it addresses are not present.

In optional applications, the inventive system may be used to control recovery of liquids into external storage containers. Such applications would require connections (not shown) of an external storage container the suction manifold 30 and vacuum manifold or vacuum pump 95.

By use of the above described system and methods, incidental liquids may be recovered in a controlled manner with complete and simultaneous record keeping. Because the transfer and volumes stored are measured and recorded at all times, the inventive system provides a record including information of all volumes transferred and, or, stored and when, and by whom, the activities occurred. Additionally, in combination with external storage containers, similar records of liquid volumes recovered and transferred, and stored, externally to the system may be produced and retained for use. By use of the inventive system, hazardous liquids may be recovered in a completely controlled and monitored fashion with complete records of

Herein, the term “hazardous liquids” is intended to mean liquids that have a harmful property. While the term is used here as a general design guide and motivation, the invention is not limited in operation to any specific liquids or type of liquids. In any particular application, the components of the system may be designed or selected to accommodate the properties of the liquids to be handled. Particularly, applications for recovery and handling of liquid hydrocarbons, such as automotive fuels oils, and lubricants, may require container materials impervious to these liquids.

The term “spill” is intended to mean a quantity of liquid residing on a working surface incidental to and adjacent the inventive system. Such a surface include the ground or floor supporting the inventive system. Particularly, the working surface is exterior to the system. A spill is typically of shallow depth such that vacuum recovery does not required lifting a column of liquid. Rather the liquid is entrained and moved as a dispersion in a moving air stream, the volume of the moving air being greater than the volume of liquid.

Herein, the terms “vacuum” and “pressure” are used to define a relative pressure state that induces the desired movement of liquid from one space to another, the terms each referring to the relative pressures in the associated space.

FIGS. 7 a and 7 b are photos of an alternative configuration of the invention in which a transmission device 220 is connected to a portable vacuum collection system 201. In this configuration, the vacuum collection system 201 includes a wheeled frame 202 supporting an electrically powered vacuum pump 205 and a connected collection container 210. The transmission device 220 is connected to the electrical power or control circuit of the vacuum pump 205 such that when the vacuum pump 205 is powered or operated, the transmission device 220 is activated.

Upon activation, the transmission device 220 sends one or more signals to one or more remote locations. The signals contain sufficient information to identify the vacuum collection system 201 and provide operation parameters. Transmitted operation parameters may include, but are not limited to, the time, location and duration of operation. Other parameters such as flow rates or levels may also be transmitted. Other signals such as photographic data or video signals obtained from frame mounted cameras may be also transmitted automatically. The transmission device should initiated and operated automatically, without human operator assistance or activities.

Inclusion of the above transmission device provides a means for remotely monitoring system operations events and collection activities through automated wireless communications. The transmission device 220 may be any of a variety of devices incorporating a cellular phone or similar devices that are also connected to a switch that is controlled by vacuum collection system circuitry or power. Alternative devices include phone and computer based communication devices using internet transmissions. 

1. A system for collection of spilled hazardous liquids comprising: a portable frame; a multiple of closed containers received in the frame and configured to receive and maintain liquids, each container having: a depth sensor for providing an electronic signal indicating the depth or volume of liquid contained in the container, an inlet port including an associated valve configured to prevent liquid from leaving the container through the inlet, an outlet; a discharge port including an associated discharge valve configured to prevent liquid from entering the container through the discharge port; a vacuum blower retained on the frame; a means of selectively connecting, alternatively, any one container inlet to the blower; an suction conduit configured to receive incidental liquids on a working surface outside and adjacent the frame; a means of connecting the suction conduit to the inlets of all the containers; and a control system, configured to control recovery into the containers while collecting and storing data identifying the volume and nature of the recovered fluid as well as user and event data.
 2. A system for collection of spilled hazardous liquids comprising, according to claim 1, and further comprising: a safety fluid volume maintained on the frame, wherein the safety fluid comprises a material rendering a flammable liquid resistant to ignition when mixed with the liquid; and means of dispensing portions of the safety fluid from the frame.
 3. An improvement in a vacuum collection system for recovering hazardous including a electrically powered or controlled vacuum pump, wherein the improvement comprises: a transmission device connected to the electrically powered or controlled vacuum pump; the transmission device configured to transmit, upon the event of the collection system being powered or operated, a signal to a remote location; the signal capable of specifying the identity and operation of the vacuum collection system. 